G1-W42-Electrical Systems and Wiring Diagrams
Contents
1. VBAT REQUEST INPUT Grm 0020 WA IT SHEET 3 UEST OUTPUT ED 08 5 SED 0 8 C200P C000 ENG CI36P i NTL W L F 1265 126 SAVEI STILL PRESENT N CANCELLED 2155 C215P NOTE 1 FIXED N LEVEL INPUT S C1965 _INTERNATIC g LOW_BRAKE JUTPI C200P C200P 0005 C187S C187P a 0 10008 P HT gt LE CHK LT g 2 VOLT REFERENCE CHASSIS FUEL LEVEL SEE NOTE ZHK LT RLY i 12 WASHER FLUID Figure 38 Instrumen2. P3 MIR C 05 i yA bob ada d Ael L I L L di j i P1 ENABLE IN R029 Figure 43 Power Assist System Azure Dynamics Series Hybrid Electric Vehicle 2006 7 Shuttle Bus MANS00666 Rev A 128 Service Manual COD1S FUSE RLY PNL ji Ref FUSE amp RELAY Internal FUSE BATT IGNITION 1 ciue 2202A F4 O 5 0 kus s YA seems since RT196 RT197 BUS l HIR CAB HEATER PMP PA o8 Pows L RED 50 06 poi 50 M NT MEE EST TK 0 8 ib Ke ce RED 08 GND bM FRAME RAIL 0 8 i d K 3 n anna FAN RED 5 0 5 E O J RED Don DRIVER SIDE 40200 ae es 00480 LINI i WHT 86 3 Ry Sp 08 REE INERT
3. Jane ions 8 nn uen a PRESSURE ORKHO 40144 SE INTERFACE WHT MANS00666 Rev A po ENGINE RUN FUEL AZD Service Manual C136S 0054 3 i 08 C1265 8000BA C2095 QUADRASTAT SHIFTER SHIFTER LAM C209P 0 8 08 C0035 SIEMENS VCU Azure Dynamics Series Hybrid Electric Vehicle 2006 7 Shuttle Bus Ref INERTIA SWITCH ef INERTIA SWITCH AP AND SPLICED INTO AND SPLICED INTO 27 AP AND SPLICED INTO 6 P AND SPLICED INTO 47 OF COQ OF OF C000 WH ENGINE HARN WH ENGINE HARN UT AND SPLICED INTO 53 CONNECTOR SIDE OF VESS WH420 PPL 0 5 VESS WH 275 LT GRN 0 5 ARNESS VH ENGINE HARNESS WH 451 BLK WHT 2 0 WH 24 LT GRN 1 0 REVERSE LAMP KHORSE INTERFACE MAN500666 Rev A 120 Figure 35 Gear Selector See REF500334
4. en x EF Dri de f settimo pst HE Pert 10 t iy sa p ed EF Du merter STATER CONROE ENG COOLANT TENP SENSOR RE 30 ME 1 wg m TE PEF bum k Finl c 00205 cozop ov Prem suis l Gear Selector PESEN Od IN SMICH REF Di ps amp Funt REF Gear Selector Tome Tp supe m 4 how emp Miror Bal To AEF hero Swila mot II REF i rp C Mir FEF meria Si 185 ACINE SE REF ABS MA QAN LON PEF Posen CN AN EF Der s CBR SECOS 3 VODE SWITCH BRAKE PEDAL SACH REF Gear Selector as SE DLE SUCH RB Dn has amp Bal H TES ura fuel 7 NUNE TO po COSGP TIS Figure 33 PCM Azure Dynamics Series Hybrid Electric Vehicle 2006 7 Shuttle Bus 500666 118 Service Manual C200P 60005 ol h IGN SI FROM INTL m p hm RE
5. 4 D Service Manual 10 Electrical Systems and Wiring Diagrams E b 29 MD 30 H H E2 p n za eT Tr m IT H fu TH ELE Eri aoa n mO 0 9 tidie i 16 204 Jm JEJE B list 02 Ref DRIVER INPUTS amp FUEL A DL DA ni ps 1 e Fi p 1 Tw E T FUSE RELAY PANEL m amp FANS Ref PUMPS amp FANS Ref ABS SYSTEM Figure 28 Fuse Pane Azure Dynamics Series Hybrid Electric Vehicle 2006 7 Shuttle Bus MAN500666 Rev A 113 Service Manual MAKI FUSES EXTERNAL FUSES LOAD DESONII 29 HV DC DC 164 FUSE POWER FOR HV DC DC OUTPUT FEED N 80 L O PS NAT AJ FUSE FOR HV JUNCTION POST 10 PS
6. N BOX LOW COOLANT FUSE POWER FOR 2ND DC DC OUTPUT FEED N JNCT B REDUNDANT STARTE i A FUSE TO 000245 HOT WHEN HV ENABLE ON RELAY BRACKET LL Ha A HV FUSE FOR D00245 N BO LN E TAR M FUSE POWER FOR STARTRANS 10405 IN BATT 80 VN LANT U R SE FOR IN BATT B SE FOR 12 N 80 CE T FUEL PVP FUEL WET COL c Hv A ER 4 MINI FUSES FEED WW GO 1013 81 REFS PIRIRAN FAN 2 PONERISEN H PACK 100 COE KI 5 Kd TOTRON GATEWAY CONTROLLER INLINE REF NTI JUO MOTOR CONTROLLER DC DC ENABLE POWER STEERING ENABLE RELAY ELECTRIC DRIVE SWITCH CAN DINCNOSTIC PORTS SPARE SPARE PORT DCO SL S FUEL INIECTORS COL ARIRAN BAT 2 BATT PACK DUO CONTROLLER ERTRAIN FA ANI ANK SIGNAL TO DI ERTRAIN FAN AOIN ER SIEERING CONTROLER F4 F5 Fi EXTERNAL RELAYS LOAD DESCRIPTI rad LOW TEVP COLANT PUVP EDUNDANT STARTE 0 NPUT IN PVP B LON COOLANT R COND ENGL OWOC 245 WERTE Wes HALO WNOSHELD WEER SPEED CTRL PERS PR INDSHELD WIPER POWER CTRL UP RY SUP UP REA Figure 29 Fuse Label Azure Dynamics Series Hybrid Electric Vehicle 2006 7 Shuttle Bus 500666
7. ESC Bold C1600 CHECK ENG 3 1 HEAD T 61995 24 7 C1200 C4008 m s Figure 31 Cab AC System A C REQUEST Azure Dynamics Series Hybrid Electric Vehicle 2006 7 Shuttle Bus 500666 116 Service Manual CO015 FUSE RLY PNL CO36P 00365 Figure 32 Inertia Switch zT WAKE HIGH y CONTACTO sm HV GATTE SIEMENS VCU 0005 T 6 1 MER INPUTS amp FUEH C001S FUSE RLY PNL Azure Dynamics Series
8. Hi Beam e KeyOn I6 Control Converter PPSI RET L EE Pu na Throtea ena Cob Instrument 11 10 5 Tura rsmsovr4 Module pwm 1 10 Cobasys rsen pt n PS HSOUT 28 PPS2 5V REF s wa Tun e REF 5 x amo 1112 masowe DICO Throttle 2 s z Sane PWM23 7 PWM 2 PPS2 Headlights PS MC 30 Siemens AN 2 ABS Warni qns Fusible PWM 2 RTN 2 PPS2 RET Dd EV Switch dash mounted RET 11 v 0 2 NO GND 7 wa 5 CPU C167 16bit 20MHz 3144 PPE I0VREF Flash 512 kbytes 77 ngine Seng RAM 256 kbytes Engine 1246 42 5 xa Brake Failure ka I EEPROM Skbytes pryg 25 Engine Oil Pressure Controller Fuel Level ADINS27 CM Park Brake GM 10VREF 1163 sie Fuel Level Bu ext cb E Sender Y or Accelerator Pedal Heating Engine On 2400 Power Assit ode on Chassis Accelerator Pedal enis Pump v e ning Bu zer pr AWA ICE Enb DOL Mandatory foi 0027 4 p ans Ius on Purolator only disconnect ns ve mm on Shuttle Bus na vi Switch ABS Active Engine Fuel MEE Pump aj Sm Bat Trans Mode B DOH 2 5 na AW Mm 0018 12 nar ans Mot amp Gen ane Sensor Ground Pump i Tn D STOP N s Brake Switch apINS a9 Safety Cut off DOH mandatory for Shuttle Bus only TEMP EXT 1S desde Brake
9. i 0 Y 100 9 ENG HARNESS WH E874 WHT 1 0 mE 95 l0g5H AND SPLICED TO 10 000 MARN LOT D y Y INC ORNS WH pto Sev AW INSTR CLUSTER Figure 46 ABS System Azure Dynamics Series Hybrid Electric Vehicle 2006 7 Shuttle Bus 500666 Rev A 131 Service Manual Powertrain CAN DB9 Powertrain CAN bus 500k bps Pin 7 IGN KEY Y L T Resistor 100 T Resistor Pis CAN2 23 37 K PPS1 SV REF Ag PWR S REFA JG ye NE 13 2 j n j hIS Back Light Dimmer Powertrain PPSI Actuator Control N NiMH v Vat PL Key Start 12VHi Effect ANA 4 Battery ADIN6 26 PWM to Analog Module TAC Vesw erede
10. 100 data PCM diag motor generator inverter temperature 7 Water in Fuel 3 Output 3 23 786 100 data PCM diag bit tags 8 Engine brake Warning Key Start Acknowledge c 24 787 100 PCM diag modes contro bits 9 Stop Warning Precharge active 25 788 100 data PCM diag vehicle control feedback its 10 RBS Disabled 9 Q 26 789 100 data PCM diag vehicle control feedback bits Tix Generic Indicator z 27 7BA 100 data PCM diag accelerator and engine variables 12 High Voltage Hazard 28 788 100 data PCM diag bit flags 13 12V Charge System 14 Seat Belt 15 Brake Warning 16 ABS 17 Service Required 18 Oil Pressure 19 Low Fuel Level 20 Drive Enabled 21 Drive 22 Power Limit Powertrain CAN 500Kbps Precharge state BMS mode Isolation Resistance Total Batt Voltage Total Batt Current Max discharge current Min regen current Siemens DUO Inverter 650V Max Batt vol Min Batt vol SOC BMS status BMS Fault i zu E s Generator Siemens Battery Control 90kW max cont amp Module BCM Y 4000rpm 110kW max peak Motor Siemens 80kw max cont 110kw max peak 9000rpm B
11. 112 0 Ji O M Azure Dynamics Series Hybrid Electric Vehicle 2006 7 Shuttle Bus MAN500666 Rev 125 AZD Service Manual HV BATT PACK 01795 C0015 FUSE RLY PNL C076P C076S Ref FUSE amp RELAY Internal BUS SUPPLY VDM MASTER SLAVE pr Ret FUSE amp RELAY Internal TUN 20489 074 0745 RED 0 8 gt SPL 028 0035 SIEMENS VCU oou HASSIS CN IGNAL CN HV J BOX A RT038 F 51 2 1007 Ha Ou O STUD 7114 J RT037 Figure 41 HV Battery Pack Azure Dynamics Series Hybrid Electric Vehicle 2006 7 Shuttle Bus MANS00666 Rev A 126 E RT197 RT198 AL BATTERY SYSTEM Service Manual 300VDC TO 12VDC CONVERTER HV PWR ENABLE ENABLE RT093 RTO92 HARE J SIEMENS VCU 00055 074 0745 CHU
12. 114 7 D Service Manual PANEL HEATSHRINK H INT m USE TEMPERATURE FUSE oE 990 4 p ISOLATION TAPE 127 LON AZD FUSE VOTE NS A USE ANTI OXIDANT COMPOUND ON ALL 12V DC POWER 68 SAN CABLES L uH ALTERNATOR 145A 4 BATIERY Figure 30 12 V Dual Battery Azure Dynamics Series Hybrid Electric Vehicle 2006 7 Shuttle Bus 500666 RevA 115 AZD Service Manual ED ProAIR CONDENSER WITH FANS WH COPRESSOR A C REQUEST INT ACCUMULATOR INT EVAPORATOR S EXPANSIOI VALVE 1 Scale NTS A C SYSTEM BLOCK DI AGRAM ESC CLUTCH CONTROLLED DI AGRAM 2 Scale NTS
13. Hybrid Electric Vehicle 2006 7 Shuttle Bus ENG RUN FUEL MANS00666 Rev A 117 I FUSE BATI IGNITION 1 INERTIA INERTIA SW CO415 TUD s n HR 14 10 kAN 14 10 17 Bk lt 40 up 5 gt 10 gt RED 10 020 uk 5 PWRTRN IGN 1 NOUIS HAN F15 E 12E E amp SES Tende 5 lt EF5003393 y sr 13 1362 C136 2 L SAVEI 7 1 Q DRMER INPUTS amp FUEL g 4 aL 0 08 Ret INSTR CLUSTER 5 54 gt 28 ic TEN f INSTR CLUSTER A GEAR SELECTOR ROUND DISTRIBUTION 2V IGNITION POWER DISTRIBUTION DISTRIBUTION INERTIA SWITCH POWER DISTRIBUTION HV BATT PACK 179 54 074 COPS INERTIA SW SPL SAVER Service Manual roue CUR wa ore os LES iE WH SHEET 20 tas 1 Harness COOIS FUSE RLY PNL gr Bee amp Relay SAA COTES core cogis COBIP Eg T D mi SP SID 4 PA SIEMENS SE Purps b Fore FAN RIY
14. PB ELEC LOOP GEAR SELECTOR MY06 W42 GAS SB Service Manual C028S C028P M 4 Ref INERTIA SWITCHA Figure 36 Powertrain CAN Azure Dynamics Series Hybrid Electric Vehicle 2006 7 Shuttle Bus SLD 0 5 TO INT L CAN BUS SHIELD 3EF500337 40260 0 5 40270 CRN 0 5 z BLK 05 X MANS00666 Rev A ATTERY V BATTERY PACK 069 0695 L 1 HOAN C PWRTRAIN CAN TERMINATOR D Service Manual 00785 CO78P C079P 07 1024 2 YEL 0 5 Figure 37 DUO CAN Azure Dynamics Series Hybrid Electric Vehicle 2006 7 Shuttle Bus 500666 Rev A 122 Service Manual 2035 C203P INLINE FUSE ET
15. RECEN DISABLE SWITCH S Ref SWITCH INERTIA WH SEE WH ai IRCUIT E LOOP DRAWINGS 500351 SPLICED INT ENGINE HARNE AGE 4 INERTIA CH 020 0205 CO01S FUSE RLY PNL ACCELERATOR PEDAL 01255 RT029 00055 SIEMENS DICO 10 OV REFERENCE ACCELERATOR SWITCH 51 WH EXT500351 FUSE BATT ENG RUN FUEL PMI 18 8 F Ret INERTIA Suite RED Figure 34 Driver Input and Fuel Azure Dynamics Series Hybrid Electric Vehicle 2006 7 Shuttle Bus SHEET 020 5 SHEET 035 PAGE 1
16. CM PCM Pack max power limits discharge and charge BRI 2 gt lt ABS Active 8 257 100 data BCM PCM Pack lifetime amp hours in lt _ Oil Pressure 9 258 100 data BCM PCM lifetime amp hours out gt 10 259 100 data BCM PCM Pack percent of life remaining 4 Gauges lt Charger On 12V effect 11 25E 1000 data BCM PCM Pack stored faults Vehicle Speed km h lt Fuel Level 12 25F one shot data BCM PCM Pack software version Battery SOC lt Brake Switch NC Active High 13 700 50 IC vehicle speed SOC fuel level temperature Fuel Level 6 Active Low 14 701 50 IC IC indicator lamps and outputs Powertrain Temperature C lt Engine Coolant Temp 15 702 100 C text tine 1 Warning Lights LCD Text M Key Start 16 703 100 IC text line 2 1 Charging Line 1 8x ASCII 4 Crash Switch 17 7BO 100 data PCM diag accelerator and brake inputs 2 Wait i z 18 7B1 100 data PCM diag generator and engine speed feedback 3 Check Engine lt Regen Disable 19 782 100 data PCM diag HV power variables 4 Cruise Low Side Outputs lt 20 7B3 100 data PCM diag generator power 5 Economy Mode 1 Output 1 21 784 100 data PCM diag motor torque battery power 6 DRL On Warning 2 Output 2 22 785
17. Dynamics Series Hybrid Electric Vehicle 2006 7 Shuttle Bus 500666 Rev 129 Service Manual NUS FUEL as MATES TO WH C400 at WH CHASSIS HARNESS MATES WH C006 WH ENGINE HARNESS LEO 5 NECTS TO WH Ci INLINE AZURE ABS DIAGNOSTICS CONNECTOR 0005 C200P i ENGINE DIAGNOSTICS CONNECTOR Figure 45 Misc Workhorse Harnesses Azure Dynamics Series Hybrid Electric Vehicle 2006 7 Shuttle Bus 500666 RevA 130 A 4 D Service Manual 0745 C074P 0035 SIEMENS DICO 0894 289 yi JN 11 2 0 IH 08 8 SIC 88 TAP AND SPLICED TO 85 OF C602
18. IA SWITCH i i U H SIDE 7 FRAME RAIL GND EN oy 2 BIO 208TA E cip F5 ENS RED 5 0 niai lt 50 020E WHT 0 8 Ref INERTIA SWITCH mo Y FRAME RAIL GND 805 COOLING PUMPS AND FANS PWRTRAIN PMP C0015 F2 N2 LN 4 9000E Ref INERTIA SWITCH 08 0 1825 1186 D CURB SIDE HV ENABLE WHT 0 8 FRAME Ref 300 DC 12V DC CONVERTER PWRTRN COOLING PUMP B WRTRN 1208058 i pn n 2 2112A RED 502 mi e RED 50 90000 Ref INERTIA 5 BLK 0 8 AT86F ENABLE 1 WHT 0 8 12V DC CONVERTERI STARTER STARTER 10200 1020 0015 T W 8 p MN WAT 08 i i 0035 SIEMENS VCU 1 30 d 5 4020 40200 L 020 PT STARTER GROU 504 0 0 P gt Bus WAT 08 WATO THROUGH HOU RTOIO R 40408 10408 4040A v9 034 I WAT 08 WAT 0 8 S CI 000 CURB SIDE FRAME RAIL GND Figure 44 Pumps and Fans Azure
19. ION BOX ALUMINUM Figure 39 HV System Azure Dynamics Series Hybrid Electric Vehicle 2006 7 Shuttle Bus 500666 Rev A 124 Service Manual DUO MTR CONTROLLER 00555 EMERGENCY Figure 40 DUO Inverter uo can MIEL Wr Key oN 23 0205 020 01795 C129P 4037E B 2V ENABLE gt WHT OR x lt SIEMENS VCU DUO INVERTER um SPL 2 v SUPPLY ED 5 se 3ATTERY PACK Ref HV BATTERY R 0565 CO36P 2c m Ref INERTIA DOOR INTERLOCK INDUCTOR TEMP 0 35 INDUCTOR TEMP 15 J BOX INDUCTOR RUE RTO44 n RI042 RTO46 w S M u 50 p 0 35 9 5 RTOAS _ RTO47 amp 1045 1 u auc 50 BLK 0 35 E 7 GENERATOR Ud O mss u 3 RTOSO ul M ORTOS 0 Poo 3 1051 ji i gt ORT057 1 8052 TRACTION MOTOR MOST
20. S w p 0 4186A w 1186C n 08 M uu gt uu 08 e REF hera Switch C TO 12VDC ZONVERTER B RTI94 BAT BOX F BAT BOX FUSE 40 Ref 12 Volt Dual Battery Syste i 4 0 1 0 RT192 RT193 CHASSIS GNE HEAT SIN RT104 Figure 42 300VDC to 12 VDC Inverter Azure Dynamics Series Hybrid Electric Vehicle 2006 7 Shuttle Bus MANS00666 Rev A IR 127 HT 0 8 T m 4186F H ja 1186E 5 8 lt HV El b LE VER Service Manual AUX HIGH VOLTAGE MTR 4 SPL jog 2 HALL F HIL 2 TEMP2 P3 MTR B 0015 ex e PNRTRAIN FM 1 5
21. Switch D020 10 Enbas E from Inductor TEMP RTN 27 A Resistor CANI 31 17 4 CAS 16 26 DUO CAN Vign DB9 p ABS Rear Wheel Speed KBS Vbat PWM22 8 P42 chassis only 9 wel ADINS 40 42 ch 7 Modul FH Lor wir T Resistor 1200 Trsosmission 0019 11 12V Starter DOH 2 5A Range Sensor HUE nv A B P No GM Vbat em Vbat Starter N 1 9 a Bi lec WS 8 R 9 0 1 D025 2 Rad Cooling Fan DON 1 Instrumentation EIE eee NE Ground 4 SwB nji 0 0 ur alus Ibl le a d i Suk Temp HV HV Chassis Ground DICO Sensor Ground D 1 0 1 DINI4 22 Fan Fan2 gt Vi T LE 1 PA Motor D028 5 Power Assist Enable DOL Tm Vien Q derer Regen Disable Switch aient Shuttle Bus only ap PWM21 6 x We 10VREF uve HV 240 6 DCDC Converter Enable DOH j Charger On Hi 12V Effect Chon Charger On Hi 12V 0017 13 1 NT eutral MES DEA PWMGOSHz 22 pem Charger X02 8 ike LT Pump 2 l y pn X01 4 note Conn On Dmy DIGG 1 Fi HV HV X02 3 5 LGND29 GND LT Pump T DC iav zz Charger Casing 3 Converter TOT Connector L GND pa 7 L Ca sm This is an external Note During normal d charger not normally operation only CH_Plug connected to vehicle is connected to ground 220kQ Kir Con Motor Shuttle Bus only Vign 16 1 16555 A
22. attery Pack 336V x 8 5Ah NiMH Liquid Cooling Power steering Controller Power steering motor PWM to Analog Converter 21 g lt lt FUE ECU Gasoline Engine GM 4 8L max 161kw 4000rpm Figure 48 Block Diagram 300V DC Converter Azure Dynamics Series Hybrid Electric Vehicle 2006 7 Shuttle Bus MANS00666 Rev A 133
23. ir Con Dimmer G d DMOC 245 Shuttle Bus only Figure 47 Vehicle Interface Azure Dynamics Series Hybrid Electric Vehicle 2006 7 Shuttle Bus 500666 Rev A 132 Service Manual ABS Rear Wheel Speed Active Low PWM Update E Drive Active Low 3 Safety Cut Off Active High GANID Rate Instrument ICE Enable Active L hex ms To Data Cluster IC gt AGINO EON 1 21A 50 cmd PCM BCM Pack connect command clear faults J Rad Cooling Fan Active Low Pack state precharge state isolation resistance A DICO gt DC DC and LT pump Enable Active High 2 250 100 data BCM fault codes SOC coolant temp PRND I 3 12V Starter Enable Active High 3 2522 100 data BCM PCM Pack voltage current 1 5 Charger Control Active Low PWM 305Hz Max and min module voltage w corresponding PCM P Power Assist Enable Active Low 4 253 200 data BCM PCM and 2 and min module temperature Engine Throttle Position A Active Low PWM 5 254 200 data BCM PCM corresponding voltage and number Acc 37 gt Engine Throttle Position B Active Low PWM 6 255 1000 data BCM PCM Pack trip amp hours in out gt gt Transmission DTC Fix Active High 7 256 100 data B
24. t Cluster Azure Dynamics Series Hybrid Electric Vehicle 2006 7 Shuttle Bus MAN500666 Rev A 123 Service Manual HV AUX p COMPRESSOR MOTOR ir waji i TO DRIVER SIDE A M OK Pw 11054 142 M X 233838 UO E REF RTS RTT re 300VDC 12VDC 300VDC 12VDC NO HV O PE el sl CONVERTER CONVERTER D BATT PACK EG U2 am U D aq zt 5 RT092 RT092 1105 RTI28 RT129 7115 7045 RTO44 RT052 41055 RTO54 RTO49 RTOSO RT051 lE I HIO po v 2 0T TO o O0 o cT z 5 lg 5 2 gt 30X LI S E x c Ex ded ect 4 z E i ys 5 z z cae 1 1 i CO98P gt E Ww og cC TTL MOTOR PHASE CN SO TE 4 4 d db 110940 RTO6 Leh Lep B TEMP SENSOR O KUWA INDUCTOR 1058 105 RTO6O RT055 RT056 057 U vw W U v MW A STUD B STUD RT046 Q 3 RT045 M z 5 17047 M 9 g 01086 18 TRACTION GENERATOR muore Q2 RT I MOTOR 05 STUD 100 INERTE AUX MOTOR CONTROLLER RTO38 04 TM STUD 17096 Hi INDUC OR HV ZWA JUNCT
Download Pdf Manuals
Related Search